INSTRUCTIONS This manual has been prepared to calculate the standard operation times needed to do individual servicing jobs. Please make full use of this standard operation time when filling out the claim request forms. 1. Warranty Period : The service jobs within warranty period are compensated by our company’s warranty agreement. 2. Job Code Number : Please use the service job codes furnished in this manual when you fill out the warranty request forms. * Note: Refer to “CLAIM SERVICE MENU” in the DOSS (DAEDONG OVERSEAS SERVICE SYSTEM) program for detail information. 3. Use the Flat Rate Schedule To help dealers correctly identify the details of service work to be done, the schedule is edited to include exploded illustrations indicating clearly the points of service and standard operation times. The exploded illustrations are provided with emphasis on DK45S(c),DK451(C), DK501(C) tractor. 4. Standard Operation Time The standard operation time is calculated based on some standard operation conditions and the time schedule is based on the service done by a mechanic with average ability and experience. 5. Standard Operation Time Setting Condition The time schedule has based on: 1. Use of farm implement service workshop installed by adequate repair condition and facilities. 2. Use of common tools, impacts and special tools. 3. Service done by a mechanic with average ability and experience. 4. Average time calculated after disassembling and servicing executed at three times. 5. Including the time to obtain necessary parts and tools. 6. The standard operation time for jobs requiring two people is listed as the time to be done by one person. Therefore, the time should not be multiplied by two. 7. The calculating unit for the standard operation time is 6 minutes, one tenth of an hour. 8. Including the actual service time and the spare time.
INSTRUCTIONS 6. Standard Operation Time Structure Standard Operation Time = [Service Time] + [Spare Time] 1. Service Time The time spent by actual service job such as disassemble, assemble, clean, maintenance, measurement or driving test. But the time spent by inspecting a special fault is excluded. 2. Spare Time The time required to do job preparation, part transportation or other miscellaneous works for service job. Spare Time Rate = Spare Time á Service Time Standard Operation Time = Service Time x (1 + Spare Time Rate) 7. R&R (Remove & Reinstall) Setting Item : To remove and reinstall the same part or a new part for replacement, R&R items consist as following; 1) R&R includes machine in shop, fluid(s) drainage, removal and placement of the group or subgroup onto a service bed for inspection(s) or replacement(s), removal from bed, installation, fluid(s) refill, adjustment(s) and operation test, if any. 2) R&R includes disassembly of a single component or group of components from a removed assembly, washing of parts, replacement(s), if any, reassembly and adjustment(s) and operation tests if necessary. 3) R&R includes substitution of one or more parts from the complete machine or from a removed group, drainage and refilling of various fluids, if necessary. 4) Disassemble(s) from the removed group, washing, inspection and measurement of components, replacement(s) and reassembly of damaged parts are excluded. 8. The conditions to be excluded from the Warranty 1) Problem resulted in any natural disaster such as fire, flood and earthquake, etc. 2) Problem resulted in owner’s remodeling or changing the specifications. 3) Using any of non-genuine part. 4) Removal or Installation of farm implements not listed in the standard operation time items. Due to our developing or improving the products, the information contained herein is subject to change without pre-notice.
TABLE OF CONTENTS E010 E020
CYLINDER BLOCK GROUP ................................................................................................................................................. 8 OIL PAN GROUP ................................................................................................................................................................. 10
E030 E040
CYLINDER HEAD GROUP .................................................................................................................................................. 12 GEAR CASE GROUP .......................................................................................................................................................... 14
E050 E070
MAIN BEARING CASE GROUP .......................................................................................................................................... 16 MUFFLER GROUP .............................................................................................................................................................. 18
E080 E090
VALVE, ROCKER ARM GROUP ......................................................................................................................................... 20 CYLINDER HEAD COVER GROUP ................................................................................................................................... 22
E100 E110
CAMSHAFT GROUP ............................................................................................................................................................ 24 PISTON, CRANKSHAFT GROUP ....................................................................................................................................... 26
E120 E130
FLYWHEEL GROUP ............................................................................................................................................................ 28 NOZZLE, HOLDER GROUP................................................................................................................................................ 30
E140 E150
FUEL CAMSHAFT GROUP ................................................................................................................................................. 32 SPEED CONTROL PLATE GROUP ................................................................................................................................... 34
E160 E170
ENGINE STOP LEVER GROUP ......................................................................................................................................... 36 GOVERNOR GROUP .......................................................................................................................................................... 38
E180 E190
WATER PUMP GROUP ....................................................................................................................................................... 40 WATER PIPE GROUP ......................................................................................................................................................... 42
E200 E220
DYNAMO GROUP ................................................................................................................................................................ 44 MANIFOLD GROUP ............................................................................................................................................................. 46
E225 T100
MANIFOLD GROUP ............................................................................................................................................................. 48 CLUTCH GROUP ................................................................................................................................................................. 50
T110 T120
CLUTCH LEVER GROUP ................................................................................................................................................... 52 CLUTCH HOUSING GROUP ............................................................................................................................................... 54
T130 T140
SHUTTLE GROUP ............................................................................................................................................................... 56 REVERSE SHAFT GROUP ................................................................................................................................................ 58
T150
SHAFT 1 GROUP ................................................................................................................................................................ 60
-3 -
TABLE OF CONTENTS T160 T170
SHAFT 2 GROUP ................................................................................................................................................................ 62 AUX. SPEED SYSTEM GROUP ......................................................................................................................................... 64
T180 T190
PTO DRIVING SHAFT GROUP ........................................................................................................................................... 66 PTO CLUTCH GROUP ....................................................................................................................................................... 68
T200 T210
PTO SHAFT GROUP .......................................................................................................................................................... 70 FRONT WHEEL DRIVING GROUP .................................................................................................................................... 72
T220 T230
SPIRAL BEVEL GEAR GROUP .......................................................................................................................................... 76 SHUTTLE FORK LEVER GROUP ...................................................................................................................................... 78
T240 T250
MAIN CHANGE FORK LEVER GROUP ............................................................................................................................. 80 HI-LOW FORK LEVER GROUP ......................................................................................................................................... 82
T270 T280
REAR DIFFERENTIAL SYSTEM GROUP ........................................................................................................................... 84 DIFFERENTIAL LOCK FORK GROUP ............................................................................................................................... 86
T290 T300 T310
BRAKE CASE GROUP ....................................................................................................................................................... 88 PLANETARY GEAR GROUP ............................................................................................................................................... 90 REAR AXLE GROUP ........................................................................................................................................................... 92
T320 T321
HYDRAULIC CYLINDER GROUP ....................................................................................................................................... 94 HYDRAULIC CYLINDER BODY GROUP ............................................................................................................................ 96
T322 T323
HYDRAULIC LIFT ARM GROUP ......................................................................................................................................... 98 HYDRAULIC LIFT CONTROL GROUP 1 .......................................................................................................................... 100
T324 T325
HYDRAULIC LIFT INNER CONTROL GROUP 2 ............................................................................................................. 102 TOP LINK BRACKETGROUP ........................................................................................................................................... 104
T330 T340
GEAR PUMP GROUP ....................................................................................................................................................... 106 PTO CLUTCH VALVE GROUP ......................................................................................................................................... 108
T350 T360
HYDRAULIC TUBE GROUP .............................................................................................................................................. 110 INLET HOSE GROUP ....................................................................................................................................................... 112
T370 T380
OIL INLET PIPE GROUP ................................................................................................................................................... 114 OUT HYDRAULIC PIPE GROUP ...................................................................................................................................... 116
-4 -
TABLE OF CONTENTS T385 T390
OUT HYDRAULIC PIPE GROUP ...................................................................................................................................... 118 POWER STEERING GROUP ........................................................................................................................................... 120
T400 T410
STEERING HOSE GROUP ............................................................................................................................................... 122 STEERING CYLINDER GROUP ....................................................................................................................................... 124
T415 T420
JOYSTICK VALVE GROUP ............................................................................................................................................... 126 FRONT DIFFERENTIAL GEAR CASE GROUP ............................................................................................................... 128
T430 T440
FRONT DIFFERENTIAL GROUP ...................................................................................................................................... 130 BEVEL PINION SHAFT GROUP ....................................................................................................................................... 132
T450 T460
BEVEL GEAR CASE GROUP ........................................................................................................................................... 134 BEVEL GEAR SHAFT GROUP ......................................................................................................................................... 136
T470 T480
FRONT AXLE CASE GROUP ........................................................................................................................................... 138 FRONT AXLE GROUP ...................................................................................................................................................... 140
T490 T500 T530
FRONT AXLE BRACKET GROUP .................................................................................................................................... 142 PROPELLER SHAFT GROUP .......................................................................................................................................... 144 BATTERY GROUP ............................................................................................................................................................. 146
T540 T550
ELECTRICAL SYSTEM 1 GROUP .................................................................................................................................... 148 ELECTRICAL SYSTEM 2 GROUP .................................................................................................................................... 150
T560 T570
ELECTRICAL SYSTEM 3 GROUP .................................................................................................................................... 152 FENDER LIGHT GROUP .................................................................................................................................................. 154
T580 T590
FRONT AXLE FRAME GROUP ......................................................................................................................................... 156 AIRCLEANER SUPPORT GROUP ................................................................................................................................... 158
T600 T610
BONNET SUPPORT GROUP ........................................................................................................................................... 160 BONNET GROUP .............................................................................................................................................................. 162
T630 T640
FUEL TANK GROUP .......................................................................................................................................................... 164 FUEL PIPE GROUP ........................................................................................................................................................... 166
T650 T660
INSTRUMENT GROUP ...................................................................................................................................................... 168 LABEL GROUP .................................................................................................................................................................. 170
-5 -
TABLE OF CONTENTS T670 T680
CLUTCH PEDAL GROUP ................................................................................................................................................. 174 BRAKE PEDAL GROUP .................................................................................................................................................... 176
T690 T700
BRAKE ROD GROUP ....................................................................................................................................................... 178 ACCELATOR GROUP ....................................................................................................................................................... 180
T710 T720
MAIN CHANGE LEVER GROUP ....................................................................................................................................... 182 HI-LOW LEVER GROUP ................................................................................................................................................... 184
T750 T760
DIFFERENTIAL PEDAL GROUP ....................................................................................................................................... 186 DOUBLE ACTING LEVER GROUP .................................................................................................................................. 188
T765 T770
DOUBLE ACTING LEVER GROUP .................................................................................................................................. 190 POSITION, DRAFT CONTROL GROUP .......................................................................................................................... 192
T775 T780
POSITION, DRAFT CONTROL GROUP .......................................................................................................................... 194 SHUTTLE LEVER GROUP ............................................................................................................................................... 196
T785 T790 T800
SHUTTLE LEVER GROUP ............................................................................................................................................... 198 HITCH GROUP ................................................................................................................................................................... 200 LOWER LINK GROUP ...................................................................................................................................................... 202
T810 T820
CHECK LINK GROUP ....................................................................................................................................................... 204 TOP LINK GROUP ............................................................................................................................................................ 206
T830 T870
LIFT ROD GROUP ............................................................................................................................................................ 208 CABIN SUPPORT GROUP ............................................................................................................................................... 210
T880 T890
STEP GROUP .................................................................................................................................................................... 212 SEAT GROUP .................................................................................................................................................................... 214
T895 T900
SUN SHADE FRAME GROUP .......................................................................................................................................... 216 ROPS GROUP ................................................................................................................................................................... 218
T905 T910
CABIN GROUP ................................................................................................................................................................... 220 AIRCON, HEATER GROUP .............................................................................................................................................. 222
T920 T930
FRONT GLASS GROUP ................................................................................................................................................... 226 DOOR GROUP .................................................................................................................................................................. 228
-6 -
TABLE OF CONTENTS T940 T950
REAR GLASS GROUP ...................................................................................................................................................... 230 ROOF GROUP .................................................................................................................................................................. 232
T960 T970
SUN ROOF GROUP ......................................................................................................................................................... 234 SWITCH GROUP ............................................................................................................................................................... 236
T980 T990
CABIN WIRE GROUP ....................................................................................................................................................... 238 FENDER GROUP .............................................................................................................................................................. 240
T991 T992
AIRCLEANER GROUP ...................................................................................................................................................... 242 MUFFLER GROUP ............................................................................................................................................................ 244
T993 T994
RADIATOR GROUP ........................................................................................................................................................... 246 AIRCON BRACKET GROUP ............................................................................................................................................. 248
-7 -
E010
CYLINDER BLOCK GROUP
-8 -
JOB CODE
DESCRIPTION
TIME DK45S
DK451
DK45Sc
DK451C
DK501
DK501C
E010001
ENGINE R & R
4.0
4.0
4.0
4.0
4.0
4.0
E010002
CYLINDER BLOCK ASS’Y R & R
12.0
12.0
12.0
12.0
12.0
12.0
E010003
OIL PUMP ASS’Y R & R
5.0
5.0
5.0
5.0
5.0
5.0
E010004
GASKET, OIL PUMP R & R
5.0
5.0
5.0
5.0
5.0
5.0
E010005
GEAR, OIL PUMP DRIVING R & R
4.5
4.5
4.5
4.5
4.5
4.5
E010006
SWITCH, OIL R & R
0.3
0.3
0.3
0.3
0.3
0.3
E010007
GUIDE, OIL GAUGE R & R
0.3
0.3
0.3
0.3
0.3
0.3
-9 -
REMARK
E020
OIL PAN GROUP
-10 -
JOB CODE
DESCRIPTION
TIME DK45S
DK451
DK45Sc
DK451C
DK501
DK501C
E020001
OIL PAN ASS’Y R & R
1.0
1.0
1.0
1.0
1.0
1.0
E020002
GASKET, OIL PAN R & R
1.0
1.0
1.0
1.0
1.0
1.0
E020003
FILTER 1, OIL R & R
1.2
1.2
1.2
1.2
1.2
1.2
E020004
O-RING R & R
1.2
1.2
1.2
1.2
1.2
1.2
-11 -
REMARK
E030
CYLINDER HEAD GROUP
-12 -
JOB CODE
DESCRIPTION
TIME DK45S
DK451
DK45Sc
DK451C
DK501
DK501C
E030001
CYLINDER HEAD ASS’Y R & R
3.0
3.0
3.0
3.0
3.0
3.0
E030002
GUIDE, INLET VALVE R & R
4.5
4.5
4.5
4.5
4.5
4.5
E030003
GUIDE, EXHAUST VALVE R & R
4.5
4.5
4.5
4.5
4.5
4.5
E030004
GASKET, HEAD R & R
3.0
3.0
3.0
3.0
3.0
3.0
E030005
TEMP SENSOR ASS’Y R & R
0.3
0.3
0.3
0.3
0.3
0.3
-13 -
REMARK
E040
GEAR CASE GROUP
-14 -
JOB CODE
DESCRIPTION
TIME DK45S
DK451
DK45Sc
DK451C
DK501
DK501C
E040001
GEAR CASE ASS’Y R & R
4.0
4.0
4.0
4.0
4.0
4.0
E040002
O-RING R & R
4.0
4.0
4.0
4.0
4.0
4.0
E040003
O-RING R & R
4.0
4.0
4.0
4.0
4.0
4.0
E040004
O-RING R & R
4.0
4.0
4.0
4.0
4.0
4.0
E040005
SUPPORT, OIL FILTER R & R
1.5
1.5
1.5
1.5
1.5
1.5
E040006
GASKET, OIL FILTER SUPPORT R & R
1.5
1.5
1.5
1.5
1.5
1.5
E040007
COVER R & R
1.5
1.5
1.5
1.5
1.5
1.5
E040008
O-RING R & R
1.5
1.5
1.5
1.5
1.5
1.5
E040009
O-RING R & R
1.5
1.5
1.5
1.5
1.5
1.5
E040010
GASKET, GEAR CASE R & R
4.0
4.0
4.0
4.0
4.0
4.0
E040011
GASKET R & R
0.5
0.5
0.5
0.5
0.5
0.5
E040012
FILTER, ENGINE OIL R & R
0.5
0.5
0.5
0.5
0.5
0.5
E040013
GASKET R & R
1.5
1.5
1.5
1.5
1.5
1.5
-15 -
REMARK
E050
MAIN BEARING CASE GROUP
-16 -
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